Interior vehicle trim panel having a sprayed expanded polyurethane layer and method and system of making same

1. A method of making a vehicle interior trim panel, the method comprising:

applying a coating on a tool;

spraying skin layer forming material on the coating to form a skin layer on the coating;

spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer on the skin layer;

removing the coating, the skin layer and the resilient layer from the tool;

positioning the coating, the skin layer and the resilient layer in a mold; and

securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim part wherein the coating forms an exterior appearance surface of the panel.

2. The method of claim 1 wherein the resilient layer has a density of 0.1 to 0.75 g/cm 3 .

3. The method of claim 2 wherein a substantial portion of the resilient layer has a thickness of 0.1 to 8.0 mm and a shore A hardness of 30 to 50.

4. The method of claim 3 wherein the resilient layer has a first portion having a first thickness of 0.05 to 4.0 mm and a second portion having a thickness of 6.1 to 15 mm.

5. The method of claim 3 wherein the expandable polyurethane reactive components comprise polyol, isocyanate and a blowing agent.

6. The method of claim 1 wherein the skin layer comprises polyurethane.

7. The method of claim 5 wherein the blowing agent comprises a delayed-action amine catalyst.

8. The method of claim 1 wherein the resilient layer comprises an elastomer.

9. The method of claim 1 wherein the rigid substrate is secured directly to the resilient layer.

10. The method of claim 1 wherein the securing step comprises injecting material into the mold when the mold is in a closed position to form the substrate, wherein the substrate has attachment members for attaching the trim panel to the vehicle.